College of Engineering and
Technology
1 Concrete Technology
Development in Mechanization
Formwork
Contents
2
Introduction
Requiremen
ts of a good
formwork
Materials for
formwork
Selection of
formwork
Formwork
systems
Formwork
striking
Releasing
agent
1. Introduction
3
1. Introduction
4
1. Introduction
5
1. Introduction
6
1. Introduction
7
Formwork, sometimes known as shuttering or
casing, is the boarding
or sheeting which is erected to contain and mould the wet
concrete
during placing and the initial hardening period.
Formwork is a temporary structure that is
required to support
and form concrete members.
False work is the complete structure erected to
support the wet
concrete.
Formwork activity accounts for 30% to 60% of
the cost of the
concrete skeleton and extends 40% to 60% of the
1. Introduction
8
PROJECT TIME FRAME ANALYSIS Formwork fixing and
FORMWORK TIME deshuttering consumes
40%
FRAME
OTHER ACTIVITIES
approximately 40% of
60%
the total project
duration.
PROJECT COST ANALYSIS
20%
FORMWORK COST Formwork material and
OTHER COST its mobilization consumes
approximately 20% of
the total cost of the
80%
project
.
Fig 1.1Project time frame and cost analysis
1. Introduction
9
Fig 1.2 Typical cost breakdown of concrete slabs
1. Introduction
10
Formwork plays an important role in safety, quality,
time, and cost
of any reinforced concrete structures.
Proper selection of formwork has greater influence:
On reducing materials and labor cost,
Improving the quality of the produced concrete and
Saving time leading to smooth running of the
projects.
Because of its temporary nature, formwork does
not get due
importance either in design, making, installation, or
removal.
“Formwork is the first step in ensuring good
1. Introduction
11
Local practice
In Ethiopian case, formwork construction is left to the
carpenters.
The technology of formworks in Ethiopia is at infant
stage.
Major problems associated with conventional formwork
systems are:
Designs of formworks are rarely practiced
Accounts little percentage of the total project cost
Labor intensive
High wastage
Limited number of reuses
Need for qualified labor force and supervision
Limited spans
1. Introduction
12
Present Scenario Worldwide A mechanized
formwork system
Buildings are growing taller
but duration is getting shorter. FOR
Duration in days not in months
& years.
CONSTRUCTIO FAST
Highly competitive market. N
Scarcity of skilled labour.
ECONOM
High quality standards. Y
LESS USAGE OF
SKILLED
LABOUR
2. Requirements of a Good
Formwork
13
A good formwork should satisfy the following:
Containment Accuracy
Rigidit
Strength Finish and re-use
y Ease of handling
potential
Good
Tightness
alignment
Econom
Access for concrete
y
Durabilit
Surface finish
y Ease of stripping
Resistance to leakage
2. Requirements of a Good
Formwork
14
A good formwork should satisfy the following:
i. it should be strong enough to withstand all
types of dead and
live loads.
ii. It should be rigidly constructed and efficiently
propped so as to
retain its shape without undue deflection.
[Link] joints in the formwork should be tight
against leakage of
cement grout.
iv. It should be constructed to permit the removal
of various parts
in desired sequence without damaging the concrete.
2. Requirements of a good
Formwork
15
A good formwork should satisfy the following:
iii. It should be as light as possible.
iv. The material of formwork should not warp or get
distorted.
v. All joints of the formwork should be stiff
so that lateral
deformation under loads is minimum.
3. Materials for Formwork
16
Formwork can be mainly made up of
Timber,
Plywood,
Steel
Aluminium
Precast concrete or
Fibreglass, used separately or in
combination.
i. Timber formwork
The timber used for the formwork should satisfy
the following
requirements:
It should be well seasoned,
It should be light in weight,
It should be easily workable with nails without
3. Materials for Formwork
17
iii. Steel formwork
Although steel shuttering costs more initially, it
may work out to be
economical in the long run due to its large number of
reuses.
The advantage of steel formwork over timber formwork
include:
i. It is stronger, more durable and have
longer life.
ii. It can be put to sufficient large number
of reuses.
iii. It can be installed and dismantled with greater ease
and speed.
iv. The quality of exposed concrete surface obtained
by use of
steel form is excellent and mostly it need no
3. Materials for Formwork
18
iv. Aluminium formwork
Enables the walls and slab to be placed
monolithically in the same
operation.
Consistent concrete shapes and finishes are obtained.
The smooth finish of the concrete greatly reduces or
eliminates the
need for costly plastering.
3. Materials for Formwork
19
s. Formwork Surface finish Re-use Re-use for Formwork Shuttering
Likely Area Where
No. material for good rough component shapes
concrete Practice Fabricatable
finish finish applied defects
1 Timber Normal/ plain 1 to 2 10 to 12 Sheeting, Flat
Uneven yes site/offsite
finish shutter frame surfaces
props
2 Plywood High class/fine 2 to 4 20 to 25 Sheeting Flat/
Ply pieces yes site/offsite
finish reasonably sticking to
curved concrete
3 Steel High class/fine 45 to 50 100 to 200 Sheeting, Any
Blowholes yes offsite
finish shutter frame
props,
accessor
ies
4 Fibre glass High class/fine 85 to 120 to 150 sheeting Any
Blowholes yes Offsite
finish 100
5 Concrete High class/fine 1 - sheeting Any
3. Materials for Formwork
s.
20 Formwork Surface finish Re-use Re-use Formwork Shuttering Likely Area Where
No. material for good for component shapes concrete Practice Fabricatab
finish rough applied defects le
finish
6 Polypropyle High class/fine 100 - 150 to sheeting Any Blowholes No Offsite
ne finish 120 180
7 Hardboard Rough/basic 1 to 2 2 To 10 sheeting Flat to Hardboard Rarely site/offsite
finish slightly pieces sticking
curved to concrete
8 Polystyrene High class/fine 1 - sheeting Generally Sticking to Occasionally site/offsite
finish flat/ curve concrete
possible
9 Rubber High 10 to 12 15 to 20 sheeting Any Poor rubber No Offsite
class/superfine may differ
finish shape of
concrete
10 Plaster of High 1 - sheeting Any Give uneven Rarely Offsite
Paris class/superfine concrete
finish surface finish
if it cracks
11 Aluminum High class/fine 20 to 40 80 to 100 Sheeting, Any Alkali in conc. Occasionally Offsite
finish shutter can react to Al,
frame props if moisture
present
4. Selection of Formwork
21
The suitability of the formwork system depends on the
following seven
parameters and their relative importance for a specific
building.
4. Selection of Formwork
22
Decision making principles in selection of formwork
system
i. Knowledge base evaluation
Factors considered
Type of finish Where fabricatable
Re-use for good finish Noise produced
Re-use for rough finish Fire resistance
Formwork component applied Liability of shuttering
damage
Shuttering shapes Formwork repairs
Likely concrete defects Ease of making
openings
Area practice Insulation properties
4. Selection of Formwork
23
Decision making principles in selection of formwork
system
ii. Project base evaluation
Contract Specialty Building Specialty
Contract type Building type
Contract conditions Structural systems
and details
Project duration Building scale
Type of concrete finish Building area
Access to Labor availability
site
Site Specialty andConstruction
Site surroundings and Construction equipments
Specialty
its used
Space for formwork Construction
Site size
fabrications
productivitysequence/
program
5. Formwork systems
Various formwork systems
Beam- slab
system
Flat slab
system
Wall- slab
system
5. Formwork systems
Conventional prop formwork system
RC. SLAB
12 TK. PLYWOOD
SEC. H-
BEAM
FOURWAY HEAD PRI. H-BEAM
CT PROP
TRIPOD
5. Formwork systems
Conventional prop formwork system
5. Formwork systems
Conventional prop formwork system
5. Formwork systems
Conventional prop formwork system
Advantages
Limitations
Initial investment is less.
Flexibilit in choic of
systems are not For
y e
suitable.
greater heights of
the
floors conventional props Requires more skilled
labour.
spacing and arrangement
shuttering
to suit various slab thickness More time consuming
Formwork material / sq
operations.
process. m of
and building configuration.
Simple shuttering & de
5. Formwork systems
Column formwork systems
Innovations have led to adjustable, reusable column
forms which can
be clamped on-site to give different column size.
Can be assembled and erected more easily than
the traditional
formwork.
Increased speed and efficiency in construction.
The simplicity of assembly and disassembly reduces
the requirement
for skilled person.
The highly engineered nature of the metalwork
system enables
precision adjustment to the formwork.
5. Formwork systems
Column formwork systems
Variable section column forms Raking column
forms
5. Formwork systems
Column formwork systems
5. Formwork systems
Table formwork system
5. Formwork systems
Table formwork system
5. Formwork systems
Table formwork system
5. Formwork systems
Table formwork system
Advantages
Limitations
Best suits for large span flat Tower
crane is a must for the
slab structural system. handling of the
table form. beams
Minimum labour required. . Can not be used for
greater
depths of the
Minimum no. of joints.
intermediate
Better surface finish.
Economical only for
large span
5. Formwork systems
Tunnel formwork system
5. Formwork systems
Tunnel formwork system
5. Formwork systems
Tunnel formwork system
5. Formwork systems
Tunnel formwork system
Advantages
Limitations
Room size steel mould. High
initial cost.
mechanizatio to make it
n. Faster construction due to high viable.
minimum repetitions required
systemat procedur unskille
ic
Good qualitye and surface
d finish. Practicall th
Handling
entir
y e e
equipment
period. required.
complete
Because of repetitive and d. Need
repetitive layouts.
labour gets trained in short
engineering must be
5. Formwork systems
Aluminum formwork system
5. Formwork systems
Aluminum formwork system
Advantages
Limitations
Custom designed to suit each High initial cost.
Faster
projectconstruction
requirements. weight pilferages
As the are are
components
speed. , higher
light
compared to requir mor attentio and
conventional
High quality finish. Superior finish e e at site,
n hence
Panels can be reused
the components no of
large Numbe of componen are
r ts
formwork materials.
Erected using unskilled accountability.
more.
labour.
times.
Component being light minimizes
5. Formwork systems
42
Special structures: Large
panel formwork
system
Fast track construction
Minimum no. of joints
Reduces grout leakage & sheath
peal off
/ bulging of concrete surface
Reduces number of handlings for
required
area
5. Formwork systems
43
Special structures: Climbing formwork system
Shifting & assembly procedure
5. Formwork systems
44
Climbing formwork system:-Travelling
Modular system
High adaptability
Short shifting times
High loadability
Superb workplace safety
5. Formwork systems
45
Special structures: Climbing formwork system
5. Formwork systems
46
Special structures: Climbing formwork system
6. Formwork striking
47
Removal of formwork is also as important as erecting it.
Before formwork can be removed the concrete must have
sufficient:
Strength to support itself
Surface hardness to resist damage
Curing.
Factors affecting formwork striking
Ambient Temperature
Layout of concrete viz. horizontal, vertical or
inclined
Type of cement used
Grade of concrete
Use of retarders, plasticizers, etc.
Feasibility of removal with props left under
6. Formwork striking
48
Factors affecting formwork striking
Standards of finish required
Structural configuration e.g. simply supported or
cantilever
Curing procedures adopted
Factors to be considered in producing required
concrete finishes of
uniform color and texture
The right concrete mix
Consistency of the concrete
Use of a constant rate of placing
Uniformity of compaction
Uniformity of face contact material
Correct choice of formwork pre-treatment
and release
6. Formwork striking
49
Formwork striking Period
OPC CONCRETE (FROM BS 8110) OPC CONCRETE (FROM EBCS 1995)
Surface temperature Stripping time
of concrete
Formwork for 18 hours
70 C 160 C and columns, walls
above
Soffit formwork to 7days
Formwork for 18 hours 12 hours slabs
columns, walls
Soffit formwork 6 days 4 days Props to slabs 14days
to slabs Soffit formwork 14days
Soffit formwork 15 days 10
days for beams
to beams and
Props to beams 21days
props to slabs
7. Releasing agents
50
Facilitate the striking or removal of the formwork.
Prevent the concrete adhering to the form face.
Most oils will fulfill the function of a release agent, but
different oils can produce blow holes or variations
in the color of concrete, affect efflorescence, or
retard the hardening of the surface.
7. Releasing agents
51
Requirements of a good releasing agent
Provide a clean and easy strike without
damage to either the
concrete face or form.
Contribute to the production of blemish free
concrete surface.
Have no adverse effect on either the form or
concrete.
Assist in obtaining maximum reuse of forms.
Not inhibit adhesion or penetration of any
subsequent finish
applied to the formed concrete surface.
Be inoffensive to the operative with regard
to odor, skin
staining etc.
7. Releasing agents
52
Types of form releasing agents
Neat oil: mineral oils and tend to produce blow holes
Neat oils with surfactant: mineral oils or
synthetics with wetting agent
Mould cream emulsions: minimize blow holes
and are good general purpose releasing agents
Water soluble emulsions: they are water
based and not recommended for good class work
Chemical releasing agents: the chemicals
react with cement to produce a form of soap at
the interface and used for high quality
Paints, lacquers, waxes and other surface
coatings: these are sealers which prevent
releasing agents being absorbed into the form
face.
8. Formwork hardware
53
Form Ties
These are devices used to hold the sides of concrete
forms together
against the fluid pressure of fresh concrete.
Ties are loaded in tension and have an end connector
that attaches
them to the sides of the form.
Some ties are designed to be removed from the
concrete after it sets
and after the forms have been removed.
The most common types of tie rods are the through
tie and lost tie
systems.
8. Formwork hardware
54
Form Ties
8. Formwork hardware
55
Form Ties: She bolt systems
8. Formwork hardware
56
Form Ties: Rapid tie system
9. Formwork economy
57
Formwork is the single largest component of concrete
building.
Considering the impact of formwork on the total
cost, the engineer should design the formwork so that
the maximum economy can be obtained.
Economy of formwork begins with the design
development of the structure itself.
The following point should be considered while
designing formwork for a building structure.
i. While designing the structure, consider the
material and tools
that will be required to make, erect, and remove the
formwork.
ii. Design the structure with standard dimensions
that will be unit multiple of forms and centering
sheets.
9. Formwork economy
58
iv. Use beams of the same depth and spacing in
every floor; this will permit the reuse of beam
forms without alteration.
v. Specify the same for columns and column-
support girders in order to reduce or eliminate
the cutting and fitting of girder forms into
column forms.
Some of the important points to achieve
economy in formwork expenditure are as follows:
i. While designing formwork, maximum usage of
material should be achieved.
ii. High quality finish on concrete surface is not
required for sides that will not be exposed.
iii. When planning forms, consider the sequence
and methods of striping.
iv. Use prefabricated panels wherever possible.
9. Formwork economy
59
v. Strip forms as soon as it is safe in order to
facilitate maximum
reuse of forms.
vi. Create cost awareness among carpenters and
other workers
involved in formwork construction.
vii. Use long length timber or plywood with out
cutting, where their
extending beyond the working area is not
objectionable.
viii. After removal clean panels and store them at a
safe place so
that they can be reused.
9. Formwork economy
60
10. Formwork design principles
61
DESIGN
Formwork should be designed in such a way that it will be
in correct
dimension, shape alignment, position, and withstand
all loads.
The basic objectives of formwork are: Quality, safety and
Economy.
To achieve this objectives the following aspects
should be considered
during formwork design
Correct assessment of loads on formwork
Selection of proper material considering
strength, durability,
and cost.
Selection of proper supporting system.
10. Formwork design principles
62
DESIGN
The detail design of formwork should take into account the
following;
a) Position of
construction joint
b) Pour size of concrete
c) Reuse of form
material
d) Clear span (or spans) with multiple
supports in between
e) Ease of stripping and re-propping of
formwork
f) Need for back propping and re-
propping
g) Supporting material
10. Formwork design principles
63
FORCES ON FORMWORK
A major cause for failure of structures during
construction is
insufficient load-bearing capacity of the formwork.
Formwork for concreting should support al loads.
i. Dead Load
The dead load includes the weight of fresh concrete
and reinforcing
steel.
The unit weight of fresh concrete including steel is 26
KN/m3.
10. Formwork design principles
64
FORCES ON FORMWORK
ii. Live Load
The following effects should be considered while
estimating live loads
on formwork.
Dumping of concrete
Movement of labor
Construction equipment
Lateral forces produced by wind
Eccentricity of the concrete weight during the
progress of work.
10. Formwork design
principles
65
FORCES ON FORMWORK
iii. Vertical Load
Both live and dead load contribute to
vertical load.
A minimum of 2.5 KN/m2 on a horizontal
plane is considered
adequate for normal construction.
iv. Lateral Pressure
An agitation (negative) pressure is caused due to
vibration of fresh
concrete. As a result of vibration, concrete is maintained
in a fluid
state.
2
10. Formwork design principles
66
FORCES ON FORMWORK
iv. Lateral Pressure
Lateral pressure on sides of formwork developed by
wet concrete is
dependent on the following factors:
Density or weight of concrete
Workability of concrete
Rate of placing
Temperature of concrete
Method of consolidating the concrete
Dimensions of section
10. Formwork design principles
67
FORCES ON FORMWORK
iv. Lateral Pressure
10. Formwork design principles
68
FORCES ON FORMWORK
iv. Lateral Pressure
ACI Committee 347 has developed a formulae for
calculation of
lateral pressure on formwork for prescribed conditions
of
temperature,
rate of placement,
vibration,
unit weight of concrete, and
slump.
10. Formwork design principles
69
FORCES ON FORMWORK
iv. Lateral Pressure
Column
With a maximum of ,a
minimum of
but in no case greater than
Wall
With a maximum of ,a
minimum of
but in no case greater than
10. Formwork design principles
70
FORCES ON FORMWORK
iv. Lateral Pressure
Where: P = lateral pressure
h = depth of plastic concrete from the top of
placement to the
point under consideration (m)
w = unit weight (KN/m3)
R = rate of displacement (m/h)
T = temperature of concrete during
placement
Cw = unit weight coefficient (as per
the table)
Cc = chemistry coefficient (as per
the table)
10. Formwork design principles
71
FORCES ON FORMWORK
iv. Lateral Pressure
Cw and C
c coefficient to be used in pressure calculation
10. Formwork design principles
72
FORCES ON FORMWORK
v. Lateral Load
Wind load falls into this category.
In general, horizontal load, w, acting in any direction
on any floor
should not be less than 150 Kg/linear meter or 2% of
the total dead
load.
vi. Special Equipment Load
If ready mix concrete or pumping of concrete is
used, formwork
should be designed for the additional pressure that
could be caused
by the method of placement.
10. Formwork design principles
73
FORCES ON FORMWORK
vii. Other Loads
The formwork must be able to withstand the following
loads also:
Shrinkage and thermal movements in the
freshly placed
concrete.
Snow load
Form design must also consider
unsymmetrical placement of
concrete.
11. Failure of formwork
74
The failure of formwork is always embarrassing and
expensive for everyone involved in the project.
Failure may be collapse of entire formwork or part of it.
Some of the reasons for the failure of formwork are
given below:
a) Improper or inadequate
shoring
b) Inadequate bracing of
members
c) Lack of control of placement of
concrete
d) Improper connection
e) Premature striping of
formwork
f) Improper design
11. Failure of formwork
75
In order to prevent failure of formwork the
following precautions should be taken:
i. The formwork should be designed properly
ii. Erection and stripping should be done only
under engineering supervision
iii. The sequence of removal should be pre-designed
and correctly executed.
76
THANK
YOU!